MODERN TECHNOLOGY OF WOOD, VENEER, PLYWOOD, PARTICLE BOARD, FIBREBOARD, BAMBOO & FOREST PRODUCTS MODERN TECHNOLOGY OF WOOD, VENEER, PLYWOOD, PARTICLE BOARD, FIBREBOARD, BAMBOO & FOREST

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MODERN TECHNOLOGY

OF WOOD, VENEER,

PLYWOOD, PARTICLEBOARD, FIBREBOARD,

BAMBOO & FOREST

PRODUCTS



Written By :

EIRI Consultants and Engineers

Sole Distributor :EIRI PROJECT CONSULTANTS & PUBLISHERS

4/54, Roop Nagar, Delhi-110007

4449, Nai Sarak, Main Road, Delhi-110 006 (India)Ph. : 91-11-23918117, 23916431, 45120361, 45626431

Fax : 91-11-23916431, 23918117 E-Mail : [email protected]

Website : www.eiriindia.org & www.eiri.inwww.eiribooksandprojectreports.com

MODERN TECHNOLOGY

OF WOOD, VENEER,

PLYWOOD, PARTICLE

BOARD, FIBREBOARD,

BAMBOO & FORESTPRODUCTS



Printed and Published by :

Distributed by :

EIRI PROJECT CONSULTANTS & PUBLISHERS4/54, Roop Nagar, Delhi-110007

Printed and Published by Sudhir Gupta for"Engineers India Research Institute", 4449, Nai Sarak, Main Road,

New Delhi-110 006 and Printed at Swastik Offset, Delhi

The book is sold subject to the condition that it shall not, by way or trade or otherwise, be lent, resold, hired out, or otherwise circulated without the publisher's prior written consent, in any form of binding or cover other than in which it is published/compiled and without a similar consent including this condition being imposed on the subsequent purchaser and without limiting the rights under copy rights reserved above, no part of this publication may be reproduced, stored inor introduced into a retrieval system, of transmitted in any form or by any means (electronic, mechanical, photocopying or otherwise), without the written prior permission of both the copyright owner and above mentioned publisher of this book. While the book has been prepared carefully, yet the publisher's printer and compiler do not hold any responsibility on the subject of the book. All disputes regarding this book are Subject to Delhi Jurisdiction only

© Copy Reserved by Sudhir Gupta, Delhi

ISBN : 978-81-89765-36-1Printed in New Delhi (India)

4449, Nai Sarak, Main Road, Delhi-110 006 (India)Ph. : 91-11-23918117, 23916431, 45120361, 45626431

Fax : 91-11-23916431, 23918117 E-Mail : [email protected]

Website : www.eiriindia.org & www.eiri.inwww.eiribooksandprojectreports.com



CONTENTS AND SUBJECT INDEX

Chapter Page No. Chapter Page No.

1

Wood-The Energy Source 1-25

- Introduction 1

- Energy Needs 5

- Wood Materials Available for 5

Energy

- Biomass Consumption 9

Classification

- Converting Wood to Energy 10

- Burning/Combustion Method 10

- Wood Fuel Estimation 13

- Other Methods of Converting 15

Wood to Energy

- Energy Uses 20

- Firewood 21

- Wood Energy for Forest 21

Based Industries

- Wood Energy for Other 24

Industries

2

Wood Carbonisation 26-43

- Definition 27

- Carbonisation 27

- Stages of Carbonization 27

- Charcoal-Composition 30

- Charcoal Yield 30

- Method of Charcoal Manufacture 31

and Equipment types vis-a-vis

Carbonization Processes

- Continuous Furnaces 39

- Operational Procedure of 39

Wood Carbonization

- Kiln Method 39

- Retort Method (The

Constantine Portables)- Operational Advantages 42

- Charcoal Quality 43

3

Saw Mill 44-50

- Introduction 44

- History of Small-Log 46

Handling and Processing Systems

4Types of Saw 51-61

- Definition 51

- The Carpenter's Hand Saw 51

- Two-man Ripping Hand Saw 52

- The Frame Saw 53

- Circular Saw 55

- Band Saws 57

5

Timber Terminology 62-68

6

Saw Types 69-76

7

Circular Saw 77-93

8

Sawing Methods 94-99

- Introduction 94

9

Operations of Saw Mill 100-130

10

How We do Manage 131-133Wood Waste

- Solid wood Waste 131




- Untreated Waste 131

- Treated Waste 132

- Waste from wood derived 133

materials

11

"Waste...? The use of 134-139

by products in the forest

products industries

- Value added products 134manufactured from

wood waste

- Animal bedding and litter 134

- Boiler fuel/Wood Pallets 135

- Chunkrete 135

- Compost amendments/Soil 135

amendments and potting soil

- Erosion control 136

- Lanfill cover 136

- Paper and Panel Products 136

- Syngas 137

- Mulch 137

- Packaging Filler 137

- Playground/Handicapped 137

access ground cover- Road Stablization/Pathways 13 8

- Market Summary 138

12

Okoume (Aucoumea 140-142

Klaineana)

- Properties 140

- Durability 141

- Seasoning 141

- Working Properties 141

- Uses 142

13

Chemical Seasoning 143-144

of Round Bamboo

14

Some tips on use of 145-149

Edge Glued boards

- End Sealing 145

- Surface Sealing 146

- Design Requirements 148

- Stress Points 149

15

Adhesives used for 150-165

Wood Products

- Introduction 150

- Classification 150

- British System of Classification 151- General Classification 151

- Glue/Adhesive Terminology 152

- Casein Glue 152

- Animal Glues 153

- Resin Glues 154

- Phenol Formaldehyde 154

Adhesives

- Urea Formaldehyde Adhesive 155

- Lignin Based Adhesive 157

- Adhesive Testing 157

16

Lamination and 166-173

Laminated Wood

Products- Introduction 166

- Lamination 166

- Laminated Wood 168

- Manufacture 169

- Lumber sorting and 170

re-grading Section-Lumber

Preparation

- Glue Spreading and Pressing 170

Section

- Advantages of Laminated Wood 171

- Wood-Metal Laminates 172

17

Technology of Veneer 174-220

and Plywood

- Or igin and History of Plywood 177

- Veneers and Veneering 179

- Veneer Logs 182

- Species used for Veneering 182

- Veneer Types 183




- Rotary-cut-Veneer 183

- Sliced Veneer 183

- Manufacture of Veneers 184

- Veneer Yield 185

- Veneer Grades 186

- Plywood 188

- Balanced Construction 189

- Properties of Plywood 191

- Advantages of Plywood 191

- World Production 192- Plywood Manufacture 193

- Pretreatment of Raw 193

Material in the Log Yard

- Production of Plywood in the Mill 195

- Veneer Production 196

- Treatment of Veneers 200

against insects and fungi 200

- Veneer Drying 200

- Preparation and further 202

Treatment of Veneers

- Patching of Veneers 202

- Mixing of Spreading the Glue 203

- Lay-up and Pressing 205

- Conditioning of Plywood Panels 208

- Finishing of Plywood Panels 208- Packing of Storage 209

- Sizes and thickness 209

- Marketing and Dispatch 209

- Moulding of Plywood 210

- Special Treatment against 210

Decay and Fire

- Uses of Plywood 211

- Types and Grades of Plywood 212

- Based on the Species Used 213

- Special Plywood 216

- Overload Panels 216

- Overlaying of Plywood 216

- "Wonder-Woods" of Ply 217

Industry

- Other forms of Plywood 218- Definition of Kinds 218

- Laminated Veneer Lumber 219

18

Adhesives for 221-233

Panel Products

- Classification of Adhesives 221

- Adhesives of Natural Origin 221

- Synthetic resin Adhesives 221

- Phenolic resins 222

- Phenol formaldehyde resin 222

- Fast/low temperature curing 223

phenol formaldehyde resin

- Amino Resins 224

- Urea Formaldehyde Resins 224

- Characteristics of UF Resins 225

- Melamine formaldehyde resin 225

- Grades of PF and UF Resin 226

Adhesives

- Isocyanate Resins 226

- Constituents of Adhesive 229

Formulations

- Catalysts 229

- Fillers and extenders 229

- Fortifiers 229

- Buffers 229

- Preservations 230- Technical Limitations 230

- Adhesives based on Blend 231

of Natural Polyphenols and

Synthetic Resins

- Tannin Adhesives 231

- Lignin Adhesives 231

- Cashewnut shell liquid 232

Based adhesives

- Inorganic Cements 232

- Prospects for Research 232

19

Beech (Fagus Species) 234-236

- Properties 235

- Durability 235- Seasoning 235

- Availability 236

- Uses 236




20

Prevention and 237-241

Control of Powder

Post borer

- Lyctid Borers 237

- Prophylactic protection of wood 238

- Preventive methods 238

- Bamboo is very susceptible 239

- Eradication of Borers 239- Heat Sterilization 239

- Fumigation 240

- Economics 241

21

Sandwich Boards 242-243

- Definition 242

- Construction 242

- Materials Used 243

- Structural Properties 243

- Uses 243

22

Manufacture of 244-286

Particleboard andComposite Products

- Definition 245

- Flavours 246

- Basic Materials 246

- Particleboard-Classification 24 7

and Types

- Flat-Platen Pressed 250

Particleboard

- Extruded Particleboard 251

- Low Density (Insulating Type) 252

Particleboard

- Medium Densi ty Particleboard 253

- High Density (Hardboad type) 253

Particleboard- Raw Materials 254

- Wood Raw Materials 254

- Additives 257

- Particleboard Manufacture 259

- Raw Material Handling and 261

and Segregation

- Particle Preparation 261

- Debarking 261

- Cutting/Flake Preparation 261


- Screen Classification 266

- Secondary Reduction of Flakes 267

- Conveying 267

- Drying 268

- Re-screening 270

- Resin Blending 270

- Forming/Matt Spreading 273- Cooling and Conditioning 279

- Trimming 279

- Additional Manufacturing 279

Operations

- Storage and dispatch 280

- Quality Control 280

- Composite Products 280

- Wood-Cement Products 281

- Bamboo Board 282

- Sawdust Board 283

- Other Boards 283

- Important Characteristics 283

and Uses of Particleboard

- Strength Properties 284

- Dimensional C haracteristics 284

- Uses 285

23

Fibreboard 287-322

Technology

- Introduction 287

- Definition 288


- Non-Compressed Fibreboard 289

(Insulation Board)

- Semi-Rigid Insulation Board 289

- Rigid Insulation Board 289

- Compressed Fibreboard 290

(hardboard)- Intermediate density of medium 290

density fibreboard

- Hardboard 290

- Specia l Densif ied Hardboards 291

- Terminology 291

- Raw Materials 293




- Wood Raw Material 294

- Additives 294

- Water 296

- History of Hardboard 297

Manufacture

- Raw Material Handling 300

- Pulp Preparation 301

- Mechanical Pulping 301

- Thermal Plus Mechanical 302

Pulping

- Chemical Plus 304Mechanical Pulping

- Explosion Process 305

- Sizing 306

- Formation 306

- Drying 308


Operations

- Hardboard 311

- Sizing 312

- Formation 312

- Pressing 315

- Tempering 316

- Humidification and Conditioning 319

- Trimming 320


Operations

- Combined Insulation Board 321

and Hardboard Operation

- Testing of Sheet Materials 321

- Uses/Applications 322

24

Manufacturing 323-362

Technology of

Pulp and Paper

- Introduction 323

- Background 324

- Historical Development 324

- The Manufacturing Process 331- Pulp 333

- Definition 333

- Pulp Production 333

- Pulp Types 334

- Pulping Processes 336

- Wood Preparation 337

- Mechanical Pulping 338

- Stone Groundwood Pulping 338

- Refiner Mechanical Pulping 340

- Thennomechanical Pulping 342

- Uses of Mechanical Pulps 343

- Merits and Demerits of 343

Mechanical Pulping

- Chemical Pulping 343

- Sulphite Process 343

- Sulphate Process 344- Semichemical Pulping 346

- Chemimechanical Pulping 347

- Washing and Bleaching 348

- Qualities and Uses of Pulp 349

- Other Operations before 350

paper manufacture

- Beating and Refining of Pulp 35 0

- Introduction of Additives 352

- Blending 353

- Forming the Paper/ 353

Sheet Formation

- Fourdrinier Type Machine 354

- The Wet End or the Wire 355

- The Press Section 355

- The Dryer Section 357

- The Calender Section 357

- Sizing 357

- Reeling and Final Cutting 358

- Cylinder Paperboard Machine 358

- Recycling Wastepaper 358

- Rayon or Artificial Silk 359

Manuracture

- Manufacture Techniques 359

- Uses 362

25

Types of Flooring 363-368

- Solid hardwood flooring 364

- Engineered or Multilayer 364

flooring

- Laminate Flooring 364

- India : The Possible 367

future course






Industry

- Downstream Processing of 409

Further processed Wood

Products-World Scenario

- Raw Materials, Smaller Logs 410

and Smarter Technology

- Sustainable Forest 410

Management Implications

32

Wood and Biomass 412-418Utilization

- Changing Nature of Timber 414

Resources

- Timber from World Forests 414

- Complete Utilization of Raw 415

Materials

33

Forest Products 419-493

- Nomenclature and Definition 42 3


- Fibres, Flosses and Coir 426

- Fibres from Leaves 426

- Flosses 427- Coir 427

- Grasses, Bamboo and Canes 427

- Bamboo 428

- Canes 429

- Distilation and Extraction 430

Products including Oil

Yielding Grasses

- The Distillation Process 433

- Oil Seeds 434

- Tans and Dyes 436

- Dyes 438

- Dyes from Leguminous Plants 439

- Exudes-Gums, Resins, 441

Oleoresins, Rubber, Latex etc

- Resins 442- Rubber 445

- Latex 445

- Lac 445

- Silk 447

- Medicinal Plants, Drugs, 448

Poisons

- Traditional Medicines 448

- Pharmaceutical Drugs 461

- Poisons 463

- Edible Products 463

- Fruits, Nuts and Seeds 464

- Flowers 468

- Palms 468

- Bamboo and Rattans 469

- Spices, Condiments and 470

Herbal Teas

- Fungi 473

- Honey 476

- Animal Protein 477

- Fodder and Feed 479

- Miscellneous 480

- Pesticides 482

- Orchid 482

- Terrestrial Orchids 483

- Epiphytic Orchids growing 484

on trees, or on rocks

- Insect Ranching 485

- Wildlife and Ecotourism 485

- Wildlife 485

- Eco-tourism 486

- Role of NTFP in the National 48 9

Economy

- Needs of Rural People 489

- The National Needs 490

- Demand-Supply Position 490

- Policy and Future 491

Management

- International Cooperation 492

34

Bamboo Mat Board, 494-505

Bamboo Mat

Corrugated Sheets &

Bamboo Floor Board

- Introduction 494- Why bamboo mat/ 495

ply board

- Technology 496

- Application of Bamboo Mat 496

Board (BMB)

- In house Construction 496




& House-hold

- In Transportation 496

- In Concrete form work 496

- Shuttering 496

- The properties of BMB 496

are comparable to plyboard

- The Properties of Bamboo 497

mat corrugated sheet

- Comparative properties 498

- Properties of Bamboo Floor 4 98

Board

- Size 498

- Colour 498

- Process 498

- Bamboo Mat Board 498

- Bamboo Mat Corrugated 500

Sheets

- Bamboo Floor Board 501

- Proposed Capacity 501

- Raw Material 501

- Plant and Equipment 502

- Building and civil Work 503

- Power Requirement 503

- Water Requirement 503

- Direct Employment 503- Indirect cont ract employment 503

- Financial analysis 504

- Break Even Point 504

- Pay Back Period 504

- Internal Rate of Return 504

35

Bamboo Shoot 506-516

- Indian Governmental Policy 506

- Facts 506

- Possibility 506

- Action Plan 506

- Introduction of Bamboo Shoots 507

- Proposed Capacity 508

- Dried Bamboo Shoots 509

- Canning of Bamboo Shoots 510

- Plant and Equipment 511

- Packaging Section 511

- Building and Civil Work 512

- Power Requirement 512

- Water Requirement 512

- Employment 512

- Estimated Project Cost 513

- Break Even Point 513

- Pay Back Period 513

- Internal Rate of Return 513

- Projected Profitability Statement 514

- Name of the Machine 515

Manufacturer

- Consultants 516

36

Cane & Bamboo 517-523

Products

- Products and Uses 517

- Market 517

- Quality 519

- Process 519- Production Target 519

- Basis and Presumption 519

- Infrastructure required 520

- Cost of shed 520

- Machinery and Tools 520

- Total Capital Cost 520

- Manpower 521

- Other Administrative 521

Overheads (per month)

- Total Working Capital 521

- Working Capital Estimation 522

- Capital Cost of Project 522

- Total Investment 522

- Sales Realization 522

Documents

MODERN TECHNOLOGY OF WOOD, VENEER, PLYWOOD, PARTICLE BOARD, FIBREBOARD, BAMBOO & FOREST PRODUCTS MODERN TECHNOLOGY OF WOOD, VENEER, PLYWOOD, PARTICLE BOARD, FIBREBOARD, BAMBOO & FOREST